USER MANUAL SRAM CORPORATION · BOXXER USER MANUAL ENGLISH BOXXER RIDE Floodgate / Floodgate / Compuerta Floodgate/ Vanne Floodgate / FloodgateOverloopbescherming / Floodgate / Compression Adjuster / Druckstufen-Einsteller / Ajustador de la compresión / Régleur de compression Regolatore della compressione / Compressieknop / Regulador de compressão / Motion Control Compression Assembly Baugruppe für Druckstufenregelung Conjunto de compresión Motion Control Assemblage de compression Motion Control Gruppo di compressione del controllo movimento Bewegingscontrole compressiemontage Unidade de compressão do controlo de movimento U-Turn Knob / U-Turn-Einstellknopf / Mando de ajuste del U-Turn / Bouton U-Turn / Pomello U-Turn / U-Turn afstelknop / Botão de U-Turn BOXXER RACE Compression Adjuster / Druckstufen-Einsteller / Ajustador de la compresión / Régleur de compression Regolatore della compressione / Compressieknop / Regulador de compressão / BlackBox Speed Stack BlackBox Speed Stack BlackBox Speed Stack Système de vitesse BlackBox Gruppo velocità BlackBox BlackBox Snelheidstapelaar BlackBox Speedstack Motion Control Compression Assembly Baugruppe für Druckstufenregelung Conjunto de compresión Motion Control Assemblage de compression Motion Control Gruppo di compressione del controllo movimento Bewegingscontrole compressiemontage Unidade de compressão do controlo de movimento U-Turn Spring U-Turn-Schraubenfeder Muelle helicoidal U-turn Ressort hélicoïdal U-Turn Molla elicoidale U-turn U-turn springveer Amortecedor de mola de U-Turn Motion Control Rebound Assembly Baugruppe für Zugstufenregelung Conjunto de rebote Motion Control Assemblage de rebond Motion Control Gruppo di ritorno del controllo movimento Bewegingscontrole terugveringsmontage Unidade de recuperação do controlo de movimento Motion Control Rebound Assembly Baugruppe für Zugstufenregelung Conjunto de rebote Motion Control Assemblage de rebond Motion Control Gruppo di ritorno del controllo movimento Bewegingscontrole terugveringsmontage Unidade de recuperação do controlo de movimento Coil Spring Schraubenfeder Muelle helicoidal Ressort hélicoïdal Molla elicoidale Springveer Mola do amortecedor Maxle Maxle DH NOTE: YOUR FORK'S APPEARANCE MAY VARY FROM THE ILLUSTRATIONS/PHOTOS IN THIS MANUAL. FOR THE LATEST INFORMATION ABOUT YOUR FORK VISIT OUR WEBSITE AT WWW.ROCKSHOX.COM. SRAM CORPORATION. · MAY 2005 3 ENGLISH SRAM CORPORATION · BOXXER USER MANUAL SRAM CORPORATION · BOXXER USER MANUAL ENGLISH BOXXER TEAM BOXXER WORLD CUP Air Cap (Positive Air) Abdeckkappe (Positiv-Luftdruck) Tapón de la válvula de aire (presión de aire positiva) Capuchon (air positif) Tappo dell'aria (aria positiva) Luchtdruk (Positieve lucht) Rosca de ar (ar positivo) Floodgate / Floodgate / Compuerta Floodgate/ Vanne Floodgate / FloodgateOverloopbescherming / Floodgate / Compression Adjuster / Druckstufen-Einsteller / Ajustador de la compresión / Régleur de compression Regolatore della compressione / Compressieknop / Regulador de compressão / Motion Control Compression Assembly Baugruppe für Druckstufenregelung Conjunto de compresión Motion Control Assemblage de compression Motion Control Gruppo di compressione del controllo movimento Bewegingscontrole compressiemontage Unidade de compressão do controlo de movimento Floodgate / Floodgate / Compuerta Floodgate/ Vanne Floodgate / FloodgateOverloopbescherming / Floodgate / Compression Adjuster / Druckstufen-Einsteller / Ajustador de la compresión / Régleur de compression Regolatore della compressione / Compressieknop / Regulador de compressão / Motion Control Compression Assembly Baugruppe für Druckstufenregelung Conjunto de compresión Motion Control Assemblage de compression Motion Control Gruppo di compressione del controllo movimento Bewegingscontrole compressiemontage Unidade de compressão do controlo de movimento BlackBox Speed Stack BlackBox Speed Stack BlackBox Speed Stack Système de vitesse BlackBox Gruppo velocità BlackBox BlackBox Snelheidstapelaar BlackBox Speedstack BlackBox Speed Stack BlackBox Speed Stack BlackBox Speed Stack Système de vitesse BlackBox Gruppo velocità BlackBox BlackBox Snelheidstapelaar BlackBox Speedstack Coil Spring Schraubenfeder Muelle helicoidal Ressort hélicoïdal Molla elicoidale Springveer Mola do amortecedor Motion Control Rebound Assembly Baugruppe für Zugstufenregelung Conjunto de rebote Motion Control Assemblage de rebond Motion Control Gruppo di ritorno del controllo movimento Bewegingscontrole terugveringsmontage Unidade de recuperação do controlo de movimento Motion Control Rebound Assembly Baugruppe für Zugstufenregelung Conjunto de rebote Motion Control Assemblage de rebond Motion Control Gruppo di ritorno del controllo movimento Bewegingscontrole terugveringsmontage Unidade de recuperação do controlo de movimento Solo Air Assembly Solo Air-Baugruppe Conjunto Solo Air Montage du Solo Air Gruppo aria Solo Solo Air-montage Unidade de Solo Air Maxle DH Maxle DH 4 95.4311.234.000, REV. B SRAM CORPORATION. · MAY 2005 5 ENGLISH SRAM CORPORATION · BOXXER USER MANUAL SRAM CORPORATION · BOXXER USER MANUAL ENGLISH Congratulations! You have the best in suspension components on your bicycle! This manual contains important information about the safe operation and maintenance of your fork. To ensure that your RockShox fork performs properly, we recommend that you have your fork installed by a qualified bicycle mechanic. We also urge you to follow our recommendations to help make your riding experience more enjoyable and trouble-free. INSTALLATION It is extremely important that your RockShox fork is installed correctly by a qualified bicycle mechanic. Improperly installed forks are extremely dangerous and can result in severe and/or fatal injuries. 1. Remove the existing fork from the bicycle and the crown race from the fork. Measure the length of the fork steerer tube against the length of the RockShox steerer tube. The RockShox steerer tube may need cutting to the proper length. Make sure there is sufficient length to clamp the stem (refer to the stem manufacturer's instructions). Install the upper crown when taking the steerer tube measurements. If using a direct mount stem, make sure the steerer is exposed 5mm above the upper crown. Use a short upper crown for head tube and headset stack heights of less than 150 mm or a tall upper crown for stack heights up to 180mm. I M P O R TA N T Consumer Safety Information 1. The fork on your bicycle is designed for use by a single or tandem bicycle, on mountain trails, and similar off-road conditions. 2. Before riding the bicycle, be sure the brakes are properly installed and adjusted. If the brakes do not work properly, the rider could suffer serious and/or fatal injuries. 3. Your fork may fail in certain circumstances, including, but not limited to, any condition that causes a loss of oil; collision or other activity bending or breaking the fork's components or parts; and extended periods of non-use. Fork failure may not be visible. Do not ride the bicycle if you notice bent or broken fork parts, loss of oil, sounds of excessive topping out, or other indications of a possible fork failure, such as loss of shock absorbing properties. Instead, take your bike to a qualified dealer for inspection and repair. In the event of a fork failure, damage to the bicycle or personal injury may result. 4. Always use genuine RockShox parts. Use of aftermarket replacement parts voids the warranty and could cause structural failure to the shock. Structural failure could result in loss of control of the bicycle with possible serious and/or fatal injuries. 5. Use extreme caution not to tilt the bicycle to either side when mounting the bicycle to a carrier by the fork drop-outs (front wheel removed). The fork legs may suffer structural damage if the bicycle is tilted while the drop-outs are in the carrier. Make sure the fork is securely fastened down with a quick release. Make sure the rear wheel is fastened down when using ANY bike carrier that secures the fork's drop-outs. Not securing the rear can allow the bike's mass to side-load the drop-outs, causing them to break or crack. If the bicycle tilts or falls out of its carrier, do not ride the bicycle until the fork is properly examined for possible damage. Return the fork to your dealer for inspection or call RockShox if there is any question of possible damage (See the International Distributor List). A fork leg or drop-out failure could result in loss of control of the bicycle with possible serious and/or fatal injuries. 6. Only mount cantilever-type brakes to the existing brake posts. Forks with hangerless style braces are only designed for `V'- style or hydraulic cantilever brakes. Do not use any cantilever brake other than those intended by the brake manufacturer to work with a hangerless brace. Do not route the front brake cable and/or cable housing through the stem or any other mounts or cable stops. Do not use a front brake cable leverage device mounted to the brace. 7. Observe all owner's manual instructions for care and service of this product. ROCKSHOX FORKS ARE DESIGNED FOR COMPETITIVE OFF-ROAD RIDING AND DO NOT COME WITH THE PROPER REFLECTORS FOR ONROAD USE. YOUR DEALER SHOULD INSTALL PROPER REFLECTORS TO MEET THE CONSUMER PRODUCT SAFETY COMMISSION'S (CPSC) REQUIREMENTS FOR BICYCLE STANDARDS IF THE FORK IS GOING TO BE USED ON PUBLIC ROADS AT ANY TIME. ! WARNING DO NOT ADD THREADS TO ROCKSHOX THREADLESS STEERERS. THE STEERER TUBE CROWN ASSEMBLY IS A ONE-TIME PRESS FIT. REPLACEMENT OF THE ASSEMBLY MUST BE DONE TO CHANGE THE LENGTH, DIAMETER OR HEADSET TYPE (THREADED OR THREADLESS). DO NOT REMOVE OR REPLACE THE STEERER TUBE. THIS COULD RESULT IN THE LOSS OF CONTROL OF THE BICYCLE WITH POSSIBLE SERIOUS AND/OR FATAL INJURIES. 2. Install the headset crown race (29.9mm for 1 1/8" steerers) firmly against the top of the fork crown. Install the fork assembly on the bike. Adjust the headset until you feel no play or drag. (Note: all upper crown pinch bolts and stem steerer pinch bolts must be loose to adjust headset properly) Make sure that the minimum distance of exposed upper tube between the fork's dust wiper and bottom of lower crown is the same as the fork's maximum travel: Fork Model World Cup/Team/Race Ride* Minimum Upper Tube Exposure 203 mm 178 mm * NOTE: FOR BOXXER RIDE, THE U-TURN KNOB MUST BE TURNED FULL COUNTERCLOCKWISE UNTIL THE GRADIENT MARKED AS 178MM IS EXPOSED. IT MAY BE NECESSARY TO LIFT THE FRONT WHEEL OFF THE GROUND AFTER MAKING U-TURN ADJUSTMENTS TO ALLOW THE FORK TO FULLY EXTEND. THIS IS DUE TO THE WEIGHT OF THE BICYCLE AND LIGHT SPRING RATE. 3. 4. 5. Install the brakes according to the manufacturer's instructions and adjust brake pads properly. Use the fork only with disc style brakes mounted through the provided mounting holes. Apply grease or anti-seize to the axle. Set the wheel in the recesses of the dropouts and insert the 20 mm axle. Torque the axle bolt to a maximum of 40 to 60 in-lb. Tighten axle clamp bolts to 20 to 30 in-lb max. Keep in mind tire clearance as you choose tires. Maximum size is 2.7 x 26" wide or 710 mm diameter installed. Be sure to check this diameter whenever you change tires. To do this, remove the top caps and spring stack assemblies and compress the fork completely to make sure at least 5 mm of clearance exists between the top of the tire and the bottom of the crown. Exceeding maximum tire size will cause the tire to jam against the crown when the fork is fully compressed. The upper tubes must always be fully engaged in the crown with no more than 160 mm of exposed upper tube above the lower crown. 6 95.4311.234.000, REV. B SRAM CORPORATION. · MAY 2005 7 ENGLISH SRAM CORPORATION · BOXXER USER MANUAL SRAM CORPORATION · BOXXER USER MANUAL ENGLISH MAXLE /M AXLE DH Q UICK RELEASE SYSTEM clear imprint in the palm of your hand, tension is insufficient. To increase tension, open the quick release lever turn the quick release lock nut in small increments until proper tension is felt. IMPORTANT Consumer Safety Information The Maxle Quick Release system allows the use of a standard 20 mm X 110 mm thru-axle hub for enhanced stiffness. The axle threads into the left fork leg, tightening the hub against the left drop out. The axle is fixed in place in the lower leg by the Maxle Quick Release lever. Riding with an improperly installed wheel can allow the wheel to move or disengage from the bicycle, causing damage to the bicycle, and serious injury or death to the rider. It is essential that that you: · Ensure that your axle, dropouts, and quick release mechanisms are clean and free of dirt or debris. · Ask your dealer to help you understand how to properly secure your front wheel using the Maxle Quick Release System · Apply the correct techniques when installing your front wheel · Never ride y ...